Adaptable universal method for producing synthetic products

Abstract

The invention relates to a method for the chemical conversion of mixtures of materials produced from solid and liquid hydrocarbons into gas/vapor mixtures and carbonaceous materials by thermal actions, catalysis and other processes and a device comprising jacket-heated, vertically and horizontally oriented reactors known per se with conveying devices and further apparatus in a process cycle.

The invention claimed is: 
     
       1. A method for producing synthetic products, which are produced from solid and liquid hydrocarbons, into a gas/vapour mixture and a carbonaceous material by thermal action and catalysis, wherein:
 a first process comprising processes that in a main reactor, in a conversion section, in a secondary reactor and in a cracking reactor, effectuate a chemical conversion of materials, and in a second process, comprising oil capture and conditioning processes, a capture of noxious substance components, a char/oil capture and separation, a gas scrubbing, a circulation evaporation, and a mixing and separation of materials is carried out, 
 in the first process, hydrocarbons undergo a multistage depolymerisation reaction and a cracking reaction in the main reactor and also in a subsequent gas/vapour reaction in the conversion section and in the secondary reactor and in the second process produced substances undergo fractionated condensation, purification, separation, evaporation, mixing and conditioning, wherein components produced are conducted through processes of one or both of the first and second processes in cycles, 
 in the main reactor in the first process, an anisotropic material mixture in form of a fill is fed into a carbonaceous mixture, and wherein steam, a carbon oxide-containing vapour mixture, a permanent gas, an oil-soluble substance, an organic vapour component, an oil, carbon and a product gas mixture are introduced and undergo an indirect heating via a heat module in a heating process, 
 the anisotropic material mixture comprises particles and is mechanically separated, and in a downwardly directed material flow of a cracking reaction, and wherein evaporation is combined with a production of a concentrically directed material flow, which is carried out, as a result of which a high energy quantity per unit area passes into a core zone, 
 an upwardly conveyed mass flow of the core zone, in which core zone depolymerisation primarily takes place, is heated with previously heated particles and with simultaneous indirect heat transfer through an inner register and compressed and relaxed in a pulsating manner, 
 the downwardly directed material flow and an additional mass flow, which is conducted via a heat transfer register, in which an indirect heat supply takes place via the heat module, are mixed, and wherein the additional mass flow bridges the depolymerisation, 
 the gas/vapour mixture produced in the core zone, by cracking, evaporation and gas reaction, is introduced as the additional mass flow into a conversion process in the conversion section, and 
 the substances are fed with the downwardly directed material flow and the additional mass flow of an equilibrium reaction in the conversion section to a conveyed material flow with carbon of a char bed. 
 
     
     
       2. The method according to  claim 1 , wherein in the conveyed material flow with carbon, in a produced high-temperature char bed, an equilibrium reaction is carried out as a reduction process with heating in the heat module, in which char bed oil-soluble substances with noxious substances contained therein are introduced, which oil-soluble substances are fed from a separating processes oil separator and a char/oil separator and wherein a separating and evaporation process occurs in a circulation evaporator. 
     
     
       3. The method according to  claim 1 , wherein a low-boiling component from a char/oil separator conducted via a separating and evaporation process in a circulation evaporator and a catalytic cracking process in the cracking reactor is fed as the organic vapour component into a ring zone and to the downwardly directed material flow. 
     
     
       4. The method according to  claim 1 , wherein the gas reaction is in the gas/vapour mixture in a plurality of reaction zones arranged in a cascade in the conversion section and in the secondary reactor in the char bed with the conveyed material flow with carbon with the addition of the permanent gas, the oil-soluble substance and a noxious substance and the steam as oxygen suppliers for gas production, for the chemical conversion of oil-soluble noxious substances and for a chemical conversion of high-boiling hydrocarbons and a gas reaction is conducted, so that in the char bed of the reaction zones in the conversion section and in the secondary reactor gas flows are produced with fractions of vaporous hydrocarbons from components of the gas/vapour mixture. 
     
     
       5. The method according to  claim 1 , wherein in gas scrubbers of the second process, gas flows are scrubbed and vapour components undergo fractionated condensation by setting a temperature of scrubbing media of the gas scrubbers, which is undertaken through a mass flow overflow and heat dissipation in the heat module. 
     
     
       6. The method according to  claim 1 , wherein a low-boiling component of a separation process in a char/oil separator conducted via a catalytic cracking process in the cracking reactor is fed into a ring zone of the main reactor as the organic vapour component in order to increase an evaporation speed on a particle surface of the anisotropic material mixture. 
     
     
       7. The method according to  claim 1 , wherein a separating process is further conducted in a char/oil separator through heating in the heat module of an upper separator zone and simultaneous horizontal conveyance of media in a lower separator zone under an effect of gravitation and a differing solubility of substances in condensed components from a gas scrubber with a heavy oil component and an entrained char component and a substance flow with a water-soluble noxious substance of an aqueous component with oil contained therein and oil-soluble noxious substances are mixed together, dissolved in one another and then separated by controlling media quantities and also producing and setting a phase boundary, in such a manner that a material flows the oil as a low-boiling component, the oil not readily dissolved with noxious substances and char suspension as an oil-soluble substance and water with char as the carbonaceous mixture and water with noxious substances and carbon, are separated from one another and discharged, wherein the water absorbs salts, is drained off and then introduced separately from a solid component into the gas scrubber, and wherein the solid component is fed as the carbonaceous mixture to the anisotropic material mixture and liquid organic components are conducted back into the secondary reactor as oil-soluble substances. 
     
     
       8. The method according to  claim 1 , wherein through a separating process in a char/oil separator, a hydrocarbon component is dechlorinated and a heavy hydrocarbon component fed from a gas scrubber with a density of water, which contains char dust as a solid, and a light oil component fed from the second process, which is lighter than water and in which noxious substances and solubilizers for oil and water in a form of quinoid and phenolic systems are contained, are mixed and fed to a reaction process in the secondary reactor. 
     
     
       9. The method according to  claim 1 , wherein in an upper region of the core zone at temperatures below 500° C. and under the conditions, dechlorination takes place and vapours thereby produced jointly in the steam are discharged into the gas scrubbing. 
     
     
       10. The method according to  claim 2 , wherein in gas scrubbers of the second process, gas flows are scrubbed and vapour components undergo fractionated condensation by setting a temperature of scrubbing media of the gas scrubbers, which is undertaken through a mass flow overflow and heat dissipation in the heat module. 
     
     
       11. The method according to  claim 3 , wherein in gas scrubbers of the second process, gas flows are scrubbed and vapour components undergo fractionated condensation by setting a temperature of scrubbing media of the gas scrubbers, which is undertaken through a mass flow overflow and heat dissipation in the heat module. 
     
     
       12. The method according to  claim 2 , wherein a low-boiling component of a separation process in a char/oil separator conducted via a catalytic cracking process in the cracking reactor is fed into a ring zone of the main reactor as the organic vapour component in order to increase an evaporation speed on a particle surface of the anisotropic material mixture. 
     
     
       13. The method according to  claim 2 , wherein a separating process is further conducted in a char/oil separator through heating in the heat module of an upper separator zone and simultaneous horizontal conveyance of media in a lower separator zone under an effect of gravitation and a differing solubility of substances in condensed components from a gas scrubber with a heavy oil component and an entrained char component and a substance flow with a water-soluble noxious substance of an aqueous component with oil contained therein and oil-soluble noxious substances are mixed together, dissolved in one another and then separated by controlling media quantities and also producing and setting a phase boundary, in such a manner that a material flows the oil as a low-boiling component, the oil not readily dissolved with noxious substances and char suspension as an oil-soluble substance and water with char as the carbonaceous mixture and water with noxious substances and carbon, are separated from one another and discharged, wherein the water absorbs salts, is drained off and then introduced separately from a solid component into the gas scrubber, and wherein the solid component is fed as the carbonaceous mixture to the anisotropic material mixture and liquid organic components are conducted back into the secondary reactor as oil-soluble substances. 
     
     
       14. The method according to  claim 2 , wherein through a separating process in a char/oil separator, a hydrocarbon component is dechlorinated and a heavy hydrocarbon component fed from a gas scrubber with a density of water, which contains char dust as a solid, and a light oil component fed from the second process, which is lighter than water and in which noxious substances and solubilizers for oil and water in a form of quinoid and phenolic systems are contained, are mixed and fed to a reaction process in the secondary reactor. 
     
     
       15. The method according to  claim 2 , wherein in an upper region of the core zone at temperatures below 500° C. and under the conditions, dechlorination takes place and vapours thereby produced jointly in the steam are discharged into the gas scrubbing.